Part 2
TRANSAXLEDISASSEMBLY AND ASSEMBLY (continued)
ASSEMBLY
1. Install the differential sub-assembly in the transaxle case.
2. Install the input shaft sub-assembly and output shaft No.1 sub-assembly in the transaxle case simultaneously.
3. Install the output shaft No.2 sub-assembly in the transaxle case as shown in the illustration.
4. Set the reverse idler gear, the needle roller bearing, the reverse idler thrust washer and the reverse idler gear shaft.
NOTE: Fit the projection of the anti-rotation for the reverse idler thrust washer into the reverse idle gear shaft as shown.
5. Install them to the transaxle case.
6. Install the gear shift fork assembly No.1.
7. Install the gear shift head No.3 and gear shift fork shaft No.5.
8. Insert the shift arm into the transaxle case, fitting it in the groove of the gear shift fork shaft No.5.
9. After insert the pivot into the transaxle case and the shift arm, install the E-ring into the arm pivot.
10. Install the gear shift fork assembly No.2.
11. Insert the shaft No. 2 in the order of gear shift fork assembly No.2, gear shift head No.2 with the shift arm and transaxle case.
12. Stick the slotted spring pin in the gear shift head No.2, gear shift head No.3 and gear shift fork No.2.
13. Insert the shaft No.1 in the order of fork No.2, No.1 and the transaxle case.
14. Tighten the washer based hexagon bolts to the specified torque.
Tightening torque: 20 ± 4 Nm (15 ± 3 ft-lb)
15. Install the reverse shift fork and the gear shift fork assembly No.3.
16. Insert the gear shift fork shaft No.3 in the order of gear shift fork assembly No.3, reverse shift fork, and transaxle case.
17. Insert the gear shift fork shaft No.4 in the order of reverse shift fork and transaxle case.
18. Tighten the washer based hexagon bolts to the specified torque.
Tightening torque: 20 ± 4 Nm (15 ± 3 ft-lb)
19. Install the ball, the compression spring, the shift detent ball seat spring No.1 and the new straight screw plug with head to specified torque (four places).
Tightening torque: 23 ± 6 Nm (17 ± 4 ft-lb)
20. Install the oil separator to the transmission case and tighten the bolts to the specified torque.
Tightening torque: 8.5 ± 2.5 Nm (75 ± 22 in-lb)
21. Apply a 1.2 mm (0.0472 inch) diameter bead of sealant as illustrated onto the transmission case.
Specified sealant: Mitsubishi Part No. MD994421 or equivalent
22. Before installing the transaxle case, confirm that the reverse idler gear mounting hole is positioned as shown in the illustration.
23. Install the transaxle case to the transmission case and tighten the bolts to the specified torque.
Tightening torque: 30 ± 5 Nm (22 ± 4 ft-lb)
24. Extend the hole snap ring and install it on the radial ball bearing.
25. Install stud bolt to the output shaft No.1 sub-assembly.
26. Pull the output shaft No.1 sub-assembly in the direction as shown in the illustration and fit the hole snap ring into the bearing groove.
NOTE: After installation, keep the sealed area away from oil for approximately one hour.
27. Push the input shaft sub-assembly in the direction as shown in the illustration and fit the hole snap ring into the bearing groove.
28. Lift the output No.1 sub-assembly.
29. Confirm that the dimension between the centers of 2.5 mm (0.335 inch) holes on the hole snap ring is in accordance with the illustration.
30. Check the hole snap ring fits securely into the bearing groove.
31. Install the reverse idler gear mounting bolt and gasket to the specified torque.
Tightening torque: 80 ± 10 Nm (59 ± 7 ft-lb)
32. Apply a 1.2 mm (0.0472 inch) diameter bead of sealant as illustrated onto the control shaft cover.
Specified sealant: Mitsubishi Part No. MD994421 or equivalent
33. Install the shift and select lever shaft assembly to the transaxle case and tighten the bolts to the specified torque.
Tightening torque: 19 ± 3 Nm (14 ± 2 ft-lb)
34. Install the straight pin to the specified torque of 30 ± 9 Nm (22 ± 7 ft-lb).
Tightening torque: 19 ± 3 Nm (14 ± 2 ft-lb)
35. Install the lock ball assembly and tighten to the specified torque.
Tightening torque: 30 ± 8 Nm (22 ± 6 ft-lb)
36. Install the filler plug and new gasket and tighten to the specified torque.
Tightening torque: 39 ± 12 Nm (29 ± 9 ft-lb)
37. Install the drain plug and new gasket and tighten to the specified torque.
Tightening torque: 39 ± 12 Nm (29 ± 9 ft-lb)
38. Apply a 1.2 mm (0.047 inch) diameter bead of form-in-place gasket (FIGP) to the drain plug along its circumference as shown in the drawing.
Specified sealant: Mitsubishi genuine sealant Part No. MD997740 or equivalent
39. Using the 27 mm (1.06 inches) socket wrench, Install the new straight screw plug with head and tighten to the specified torque.
Tightening torque: 55 ± 16 Nm (41 ± 12 ft-lb)
40. Install the straight screw plug with head and tighten to the specified torque.
Tightening torque: 23 ± 6 Nm (17 ± 4 ft-lb)
41. Apply grease to the hole and the sides of control bell crank dust cover.
Specified grease: Mitsubishi Part No. 0101011 or equivalent
42. Install the selecting bell crank assembly and control bell crank dust cover to the transmission case and tighten the bolts to the specified torque.
Tightening torque: 19 ± 3 Nm (14 ± 2 ft-lb)
43. Install the control cable bracket with transaxle hanger case No.1 to the transmission case and tighten the bolts to the specified torque.
Tightening torque: 19 ± 3 Nm (14 ± 2 ft-lb)
44. Install the wiring harness clamp bracket to the transaxle case and tighten the bolt to the specified torque.
Tightening torque: 9.0 ± 2.0 Nm (80 ± 17 in-lb)
45. Install the lock ball assembly and tighten to the specified torque.
Tightening torque: 39 ± 12 Nm (29 ± 9 ft-lb)
46. Install the backup light switch assembly and tighten to the specified torque.
Tightening torque: 40 ± 12 Nm (30 ± 8 ft-lb)
47. Install the new clamp to the transmission case and tighten the bolt to the specified torque.
Tightening torque: 12 ± 4 Nm (102 ± 40 in-lb)
48. Connect the backup light switch harness connector to the control cable bracket.
49. Install the speedometer driven gear assembly to the transaxle case.